FRN-MST-PPL-PL1-011

METHOD STATEMENT FOR NDT

Revision:P4-C

Status: IFR

Date:20.08.2015

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DOCUMENT REVISION HISTORY SHEET

REVISION
DESCRIPTION

DATE
ISSUED

P4-A

DIC

17.08.2015

Discipline Internal Check

P4-B

IDC

18.08.2015

Inter-Discipline Check

P4-C

IFR

32.08.2015

Issued for Review

Rev.

UPDATE / AMENDMENT DETAILS

HOLDS

No.

Section

Description

Input
From

Planned
Date

FRN-MST-PPL-PL1-011

METHOD STATEMENT FOR NDT

Revision:P4-C

No.

Status: IFR

Date:20.08.2015

TABLE OF CONTENTS

Page 4 of 18

Page No

1.

INTRODUCTION ................................................................................................................... ...5

2.

PURPOSE..5

3.

SCOPE ...5

4.

REFERENCES......6

5.

DEFENITIONS ..................................................................................................................... ....7

6.

ABBREVIATIONS....7

7.

GENERAL..7

8.

RESPONSIBILITIES...10

9.

NDT TECHNICIAN CERTIFICATION..12

10.

QA/QC...12

11.

HEALTH AND SAFETY PROCEDURE...13

12.

ENVIRONMENTAL REQUIREMENTS....14

FRN-MST-PPL-PL1-011

METHOD STATEMENT FOR NDT

Revision:P4-C

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Date:20.08.2015

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1. INTRODUCTION
TANAP DOALGAZ LETM A.., a joint stock company (hereinafter referred to as
TANAP) has awarded the contract for LOT 1 to FERNAS INSAAT A.S for the Trans
Anatolian Natural Gas Pipeline Project, 56 Onshore Pipeline Construction LOT 1,
(hereinafter referred to as the Project) The project details are outlined below:

Project Title

Trans Anatolian Natural Gas Pipeline Project

Project Section

Onshore Pipeline Construction Lot-1 Turkey

Contract Award Date

23.12.2014

Mechanical Completion

25.12.2017

System Handover

30.06.2018

This Method Statement will be applicable for the automatic welding operations for Lot-1
at TANAP Trans Anatolian Natural Gas Pipeline Project under the scope of FERNAS
work and fulfilling the requirements of Project Specifications and standards adhering to
EPCM Quality and Health Safety & Environmental requirements.

2. PURPOSE
This Method Statement describes the minimum requirements to be complied with for
the NDT (Non Destructive Testing) for completed welds including repairs and covers all
aspects of the entire works to ensure acceptable weld quality and shall describe the
methods of operation, implementation, requirements, reporting and recording of all
NDT operations as performed by FERNAS.
The principal objective of this Method Statement is to:
Set guidelines for how operations are performed.
Ensure all completed welds meet project requirements and specifications

3. SCOPE
The scope of work will encompass the all NDT (excluding AUT) works to be carried out
as specified in WRP-SPC-MTE-PLG-006 and WRP-SPC-PPL-PLG-001 and also the
requirements of Appendix A Technical Specification for 56 Onshore Pipeline
Construction Lots 1, 2 and 3, Appendix J: Quality Management for 56 Onshore
Pipeline Construction Lots 1, 2 and 3. This document describes the procedure for the
performance and control of all NDT operations covering all welding operations and
repairs.

FRN-MST-PPL-PL1-011

METHOD STATEMENT FOR NDT

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4. REFERENCES

BCH-AGR-CNT-GEN-040 BCH-AGR-CNT-GEN-040 BCH-AGR-CNT-GEN-040 ILF-MAN-HSM-GEN-001 TNP-PLN-HSM-GEN-005 Requirements

WRP-SPC-MTE-PLG-006 Pipelines
WRP-SPC-PPL-PLG-001 FRN-PLN-QAC-PL1-001 FRN-PLN-PRM-PL1-002 FRN-PCD-QAC-PL1-015 FRN-PCD-QAC-PL1-005 FRN-MST-PPL-PL1-010 FRN-PCD-QAC-PL1-007 FRN-PCD-QAC-PL1-009 FRN-MTX-QAC-PL1-200 FRN-MTX-QAC-PL1-300 FRN-PLN-HSE-PL1-001 FRN-PLN-ENV-PL1-001 FRN-PLN-ENV-PL1-003 FRN-PLN-ENV-PL1-010 FRN-PLN-ENV-PL1-009 FRN-PLN-ENV-PL1-012 FRN-PLN-QAC-PL1-033 FRN-PCD-QAC-PL1-009 FRN-PCD-QAC-PL1-010 FRN-PCD-QAC-PL1-012 FRN-PCD-QAC-PL1-013 FRN-PCD-QAC-PL1-014 API Standard 1104 21st Ed-

Appendix A Technical Specification\Scope of Work

Appendix J: Quality Management
Appendix K: Health and Safety for Construction
Health and Safety Manual for Construction
CONTRACTOR Health and Safety General
Specification for Welding and NDT of Onshore
Pipeline Construction Specification
Project Quality Plan
Contract Execution Plan
Procedure for Weld Joint Repair
Procedure for Mainline Welding Operations
Method Statement For Automatic Welding
Procedure for Weld Joint Numbering
Procedure for Visual Examination
Automatic Welding Matrix
Manual Welding Matrix
H&S Management System & Plan
Environmental Social Management Plan (ESMP)
Construction Impact Management Plan
Emergency Response Plan (ERP)
Pollution Prevention Plan (PPP)
Waste Management Plan (WMP)
ITP for Pipeline Construction
Procedure for Visual Examination
Procedure for Radiographic Inspection
Procedure for Manual Ultrasonic Inspection
Procedure for Liquid Penetrant Examination
Procedure for Magnetic Particle Inspection
Welding of Pipelines and Related Facilities

All stated procedures and specifications referenced in this procedure shall be code C1 or
C2 before commencement of execution of this procedure.

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DEFINITIONS

TANAP
WORLEYPARSONS PROJE YNETIMI VE
MHENDISLIK LIMITED SIRKETI
CONTRACTOR - FERNAS
SUB-CONTRACTOR
CRC-EVANS For Automatic Welding
PROJECT
- TRANS ANATOLIAN NATURAL GAS PIPELINE PROJECT
SHALL
- A requirement, meaning it must be implemented, and its
implementation verified.
SHOULD
- Should is used to indicate a goal which must be addressed
but is not formally verified.
SUPPLIER
- Organisation or person that provides a product.
MUST
- Something that is essential

6.

CLIENT
EPCM

ABBREVIATIONS

TANAP EPCM CM
SM
SS
QCI ROW JSA RH
AUT IQI
MUT LPE -

Trans Anatolian Natural Gas Pipeline

Engineering, Procurement, Construction, Management
Construction Manager
Site Manager
Site Supervisor
Quality Control Inspector
Right of Way
Job Safety Analysis
Relative Humidity
Automatic Ultrasonic Testing
Image Quality Indicators
Manual Ultrasonic Inspection
Liquid Penetrant Examination

7. GENERAL
This Method Statement shall cover all NDT operations that may be carried out for field
welding operations and for any NDT requirements in camp workshops/yards and
stockyards. This Method Statement shall not cover AUT operations which are covered
by FRN-MST-QAC-PL1-001 Method Statement for AUT Inspection, and all NDT works
shall be carried out in accordance with the relevant requirements of API 1104 19th
edition and Client Specification WRP-SPC-MTE-PPLG-006 Specification For Welding
and NDT of Onshore Pipelines and approved FERNAS NDT Procedures.

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FERNAS will ensure that following the guidelines set forth for the procedure
qualification are followed as well as ensuring that the steps involved in organizing
individuals to perform their tasks are done in a timely and professional manner.
7.1

X-RAY Operations

X-Ray operations shall be carried out by a separate crew operating on the instructions
of the FERNAS NDT coordinator and after notification to EPCM/Client. Typically the
crew will consist of the following,
1 X-Ray Crawler Operator
1 X-Ray Technician
1 Helper
Equipment
Light 4 WD vehicle
X-Ray unit including Crawler
X-Ray film
Screens
Survey Meter
IQIs
Survey meter
Densitometer
Personal Dosimeters
Small hand tools/rags/cleaning equipment
Small ladders
Film Viewer
Film Developing equipment
Film Developing Chemicals
The X-Ray crew will travel to the location as specified by the NDT coordinator and
begin to set up X-ray equipment, barriers and safety signage and equipment. The NDT
coordinator shall have liaised with the Construction team to ensure the most suitable
timing for X-ray operations to occur where the least possible amount of passing traffic
and area usage can be assured. Before any X-ray operations shall take place the XRay technician shall contact the NDT coordinator by Radio/phone to obtain clearance
to commence.
After completion of the X-Ray operation the site shall be cleared and all equipment
returned to the working base office/darkroom where films will be developed and
equipment checked and held in secure storage.
Methodology of operation and procedure shall be as per FRN-PCD-QAC-PL1-010
Procedure for Radiographic Inspection,
NOTE: A separate Work Method Statement shall be issued and approved for any
works that will utilize Gamma radiation sources.

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7.2 Multi Discipline Operations

Multi Discipline operations shall typically cover the following,

MUT (Manual Ultrasonic Testing) To include wall thickness and lamination

checks
LPE (Liquid Penetrant Examination
MPI (Magnetic Particle Inspection

Multi Discipline operations shall be carried out by a separate crew operating on the
instructions of the FERNAS NDT coordinator and after notification to EPCM/Client. The
crew may consist of one or more persons qualified to carry out MUT, LPE and MPI.
Typically the crew will consist of the following,
1 MUT/LPE/MPI technician (IE Multi discipline)
Or
1 MUT Technician
1 LPE Technician
1 MPI Technician
MUT Unit (scanner)
MUT Calibration blocks
MUT Probes
MUT Cables and accessories
Couplant
LPE Penetrant and Developer chemicals
Cleaning agent/rags
White light unit
AC Electromagnetic Yoke
Power unit (generator)
Lifting bar
Gauss meter
Light meter
MPI Powder and Contrast Paint
Small hand tools/rags/cleaning equipment
Small ladders
The multi-discipline crew will travel to the location as specified by the NDT coordinator
and begin to set up equipment as required. The NDT coordinator shall have liaised with
the Construction team to ensure the most suitable timing for NDT operations to occur

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where the least possible amount of passing traffic and area usage can be assured
dependent on location. The multi discipline crew can work in conjunction with other
teams (such as welding) as required however this should be well coordinated and
controlled.
After completion of the NDT operations the site shall be cleared and the team moved to
the next location or returned to the working base office/darkroom where reports will be
compiled and submitted.

8.

RESPONSIBILITIES
8.1

CONSTRUCTION MANAGER (CM)

8.2

The CM should ensure that all NDT operations are carried out to the
required Project Specifications.
Responsible planning of work schedules and activities.
Responsible for ensuring works are carried out as per Contractual
requirements and to approve procedures.
Responsible for all works at Site and implementation of Health, Safety
and Environmental procedures. Role: Project Quality Assurance/Control
Manager has the overall responsibility for all aspects of Quality
Management.
QUALITY MANAGER

8.3

Is overall responsible for all aspects of Quality management for all NDT
operations
To direct NDT coordinator. Lead QC Inspectors and QC Inspectors so
that All QA/QC NDT Inspection and Testing activities are performed
effectively as required by EPCM/Client
Ensures all Project documentation meets all requirements in respect of
NDT operations
Monitors reports from engineers and inspectors for trends and Non
conformances.
NDT COORDINATOR

Ensures NDT subcontractor is issued with work sheets and locations for
Inspection/Testing as per schedule.

Ensures all aspects of the NDT operation are carried out according to
apparoved procedures.

Monitor Identification and traceability

Assist in the preparation of quality records

FRN-MST-PPL-PL1-011

METHOD STATEMENT FOR NDT

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QA/QC WELDING INSPECTOR

The QA/ QC Welding Inspector shall ensure that the NDT operations
are carried out as per Project Quality Plan, Inspection and Test plan
and Client Specification: WRP-SPC-MTE-PLG-006 latest revision,
Specification for Welding and Non-destructive testing of Onshore
Pipelines.The QA/QC Inspector shall ensure that all NDT procedures
have been EPCM/ TANAP approved for the work to be carried out.

Ensure the welds are correctly marked up and identified for NDT
Ensures NDT is carried out as per specifications and approved
procedures
Ensures pipe number and joint numbers are recorded
Ensures all NDT equipment and measuring devices are properly
calibrated.
Inspection requests are raised and related QA/QA reports are prepared,
recorded and submitted for EPCM/Client approval.
Ensures the NDT consumables are properly stored, handled, and have
traceability implemented as applicable.
8.5

HSE OFFICER

8.6

Ensures that permit to work system shall be implemented where

required.
All Health, Safety & Environmental requirements shall be briefed and a
JSA/toolbox talk has been carried out before work commencement.
Ensures that Vehicles/Equipment have valid Operational Conformity
certificates.
Ensures safe working operations at NDT operations
All relevant legal documents for vehicles to be utilised shall be the last
revision and valid for the current time period.
Drivers/Operators shall be competent, holding valid driving licenses and
undergone defensive driving training
All personel involved have been inducted & hold a Safety induction
certificate, relevant machinery operation certification and permits.
NDT SUB-CONTRACTOR

Supplies NDT equipment and operators/echnicians for the performance

of NDT works
Ensures safe working operations at NDT operations according to
Project procedures
Supplies NDT consumables

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NDT TECHNICIANS CERTIFICATION

9.1 Certification
It shall be certified that the NDT Technician has successfully passed
the proficiency test as set by EPCM/Client.
After having passed the test a Technician/operator certificate is issued
by QA/QC Department for each NDT operator/technician with a unique
number.
9.2 Technician/Operator ID Cards
For the Technicians/operators who have successfully passed the
proficiency test and who have the correct qualifications the QA/QC
Department will issue a NDT Identification Card which format will be as
approved by EPCM/Client. The designation, ID no and techniques
qualified for shall be indicated on these cards.
During the NDT operations at site, all NDT workers shall possess the ID
card.

9.3 NDT Consumables

General
NDT consumable control shall be in accordance with WRP-SPC-MTEPLG-006 Specification for Welding and NDT of Onshore Pipelines and
FRN-PCD-QAC-PL1-030 Procedure for Preservation and Warehousing.
All material certification shall be held by the FERNAS QA/QC
department and MSDS shall be available with FERNAS Safety and
Environmental departments.

10.0

QA/QC INSPECTION AND TEST PLANNING

Quality assurance for this activity shall be performed by strictly following quality
procedures and by implementing QA/QC measures before, during and after welding
as detailed in this procedure by the QC welding inspector whose responsibilities are
shown in 7.6. Forms that shall be used include

Calibration Register FRN-QAC-FRM-025

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RT Examination Report FRN-QAC-FRM-033

MP Examination Report FRN-QAC-FRM-034
LP Examination Report FRN-QAC-FRM-035
UT Examination Report FRN-QAC-FRM-036

These are attached to the relevant ITPs.

Inspection, Review, Surveillance sequences and hold points for NDT operations
and consumable control shall be as shown in ITP FRN-PLN-QAC-PL1-033
11.0 HEALTH & SAFETY PROCEDURE

The radiation barrier shall be used to avoid the entrance to the radiation area.
For this purpose the international radiation signal, red on a yellow background
surrounded by radial points, shall be used.
Barriers shall be erected before starting site radiography, not during an
exposure. The barrier distance shall be calculated by a qualified operator.
The emitted leakage radiation shall in the range of permissible level by
legislation in the exposure area for operators.
Adequate warning should be given to all persons in the vicinity immediately prior
and during radiography by light or audible signal or both.
The international radiation symbol shall be placed at the entrance of the
exposure area and shall read in black on a yellow background surrounded by
radial points.
In the case of portable equipment, and once the safety area has been
determined, limit and signpost the area with the symbols called out above, as
well as with luminous and audible instruments, which will activate at the
commencement and during the radiation exposure.
During the exposure there shall be detectors to check radiation leakage of the
area.
Radiation safety areas shall be monitored and checked by quality assurance
and by authorized official organizations (Turkish Atomic Energy Institution).
.Personal Protection Equipment (PPE) requirements shall be adhered to
Tool Box Safety Talks shall be carried out prior to start of work.
Access shall be restricted and entry only for authorized individuals only.
Any equipments used shall be well maintained & to be equipped with all
required safety devices such as Reverse horn, Hazard lights, alarms etc.
All tools and tackles used for lifting shall be load tested. Visual check shall be
carried out prior to all operations to verify physical fitness of the same
Vehicles shall be maintained in good condition & Insured
Drivers must follow defensive driving skills.
No night travel other than approved deviations by EPCM
Avoid setup of work behind equipment operator.

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Water fluids and insulated tent/shelter for employees shall be made available.
Barricades, sign boards must be present at the work site/ROW.
Works shall be carried out according to Safe Construction Practices and
EPCM/Client Safety Regulations.
All personnel involved in works shall be aware of Safety requirements of the
project. The site shall be kept clean and in tidy conditions.
All access/exit points to work areas shall be maintained free from obstacles,
materials and equipment.
Physical barricading shall be placed at the work area to control any vehicle and
traffic movements.
HSE inspector shall monitor the site personnel during all welding activities.

ENVIRONMENTAL REQUIREMENTS

NDT operations shall be carried out in accordance with the requirements as

described in the Contractors Environmental Management Plan to ensure the
following items:

Environmental awareness Induction training shall be organized for all Site staff
before the start of the Construction works
All waste and metallic waste and consumable tins and packaging shall be
collected in a container and shall be disposed of at the designated waste
disposal area.
Regular Environmental monitoring and measurement activities will be performed
in any welding areas.
The site is to be left clean and tidy at all times
All Vehicle/ Machinery engines shall be switched off when not in use
Damage to the land from operation of vehicles is to be avoided or minimized
Combustion Emissions shall be minimized
Damage to the land from operation of Machinery / Equipment and vehicles is to
be avoided or minimized
Flora and Fauna that are protected under Turkish and international
Environmental Law is not to be harmed or their habitat damaged.
There shall be no discharge of chemicals to the land or into surface water.
Minimize the protect footprint. This shall include the ROW, temporary facilities
and any access roads.
In the case of a spill, the product shall be reported immediately to the
responsible Environmental Manager/ Engineer and cleaned up in accordance
with the applicable Standards.
Implementation of a solid waste strategy in line with the applicable Standards.
There shall be no unauthorized creation of access routes to otherwise
inaccessible areas.
All Ecological areas or Archaeological sites shall be protected to prevent any
damage.

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Any complaints by the public shall be reported to the Community Relation

Manager.
Implementation of corrective actions will be performed against Environmental
problems as soon as possible.
Improvement activities will be made wherever possible to enable better
performance.
No refueling will be carried out within 30 m. of any watercourse.
All Vehicles, Plant Machinery & Equipment will carry Spill response kits.

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